Clunk/Creak Noise from Front End During Low Speed Turns or Maneuvers (Transfer Replacement Rear Transmission Mount Bushing to Side Transmission Mount) #03-07-29-005B - (Jul 23, 2004) Clunk/Creak Noise from Front End During Low Speed Turns or Maneuvers (Transfer Replacement Rear Transmission Mount Bushing to Side Transmission Mount)
2000-2005 Chevrolet Cavalier
2000-2005 Pontiac Sunfire
with 5-Speed Manual Transmission (RPO MM5)
This bulletin is being revised to add model years and revise the title line. Please discard Corporate Bulletin Number 03-07-29-005A (Section
07-Transmission/Transaxle)
Condition
Some customers may comment on a clunk noise from the front of the vehicle. This condition is most common during a hard left or right turn when starting from a complete stop.
Cause
The side (front driver's location) transmission mount is a "floating"
or adjustable type of mount which may, under certain conditions, bind within the mount, causing a clunk.
Correction
To correct the creak or clunk, remove the side transmission mount and transfer a replacement rear transmission mount bushing to the existing side transmission mount. Use the procedure below.
Open the vehicle hood and remove the washer fluid reservoir cap.
Suitably support and raise the vehicle.
Remove the driver's side front wheel and tire assembly.
Remove the inner wheel well shroud bolts and retainers. Remove the inner shroud.
Remove the outer wheel well shroud bolts and retainers. Remove the outer shroud.
Remove the left fender support bolt.
Remove the washer fluid reservoir retainers, the electrical connector and the hose. Remove the reservoir.
Notice: Use a block of wood in conjunction with the transmission jack to prevent possible powertrain damage.
Support the transmission using a transmission jack and a block of wood to prevent possible pan damage.
Remove the side transmission mount bolts and transmission mount through bolt. Refer to the illustrations above. Remove the mount from the vehicle.
Important: The transmission mount is directional. It is designed to absorb powertrain vibrations in one direction only. Incorrect orientation of the replacement bushing may noticeably increase engine/powertrain vibration in the passenger compartment.
Referring to the illustration above, observe the up arrow on the illustration along with the rubber molding dimples at the 12 and 6 o'clock positions. Mark the metal portion of the mount using one or all of these indicators. You will use the marks as a guide when installing the new transmission mount bushing.
Locate the 4 metal tabs (1) in the illustration. You must bend all 4 tabs 90 degrees to facilitate the removal of the bushing.
With the 4 tabs bent in, tap the opposite side of the bushing to slide it out of the mount. You may clamp the mount in a vise if required to accomplish this task. Retention force on the bushing is low so this can be accomplished with little force.
Repeat the same procedure with the replacement rear transmission mount. You will remove the bushing in the same manner but you will not need to mark the metal mount body as it will be discarded.
Important: The transmission mount is directional. It is designed to absorb powertrain vibrations in one direction only. Incorrect orientation of the replacement bushing may noticeably increase engine/powertrain vibration in the passenger compartment.
Transfer the rubber bushing from the new rear transmission mount and install it to the original side transmission mount. Use your alignment marks to orient the new bushing in exactly the same way as the original. You must be certain that the bushing is installed in the same direction as the original or you may increase the amount of engine vibration passed to the passenger compartment.
Bend the 4 metal retaining tabs down 90 degrees until flat to the metal mount.
Install the side transmission mount and secure the bolts.
Tighten the side transmission mounting bolts.
Tighten
Tighten the mounting bolts to 75 N�m (60 lb ft).
Tighten the transmission mount thru bolt.
Tighten
Tighten the thru bolt to 60 N�m (44 lb ft).
Remove the transmission jack and wood block.
Install the washer fluid reservoir retainers, electrical connector and hose.
Install the fender brace support bolt.
Install the outer wheel well shroud and retainers.
Install the inner wheel well shroud and retainers.
Install the driver's side front tire and wheel assembly.
Lower the vehicle
Install the washer fluid reservoir cap.
Close the hood.
Parts Information
Part Number
Description
22617128
Mount, Transmission
Parts are currently available from GMSPO.
Warranty Information
For vehicles repaired under warranty use:
Labor Operation
Description
Labor Time
K2281
Mount, Transmission/Transaxle Left -- Replace
0.8 hr
Rattle/Creak/Popping Type Noise from Front of Vehicle When Turning (Replace Both Front Stabilizer Shaft Insulator Brackets) #02-03-08-008A - (May 9, 2005) Rattle/Creak/Popping Type Noise from Front of Vehicle When Turning (Replace Both Front Stabilizer Shaft Insulator Brackets)
2002-2005 Chevrolet Cavalier
2002-2004 Oldsmobile Alero
2002-2005 Pontiac Grand Am, Sunfire
with FE1 or FE2 Suspension
This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-03-08-008 (Section 03 - Suspension).
Condition
Some customers may comment on a rattle/creak/popping type noise coming from the front of the vehicle when turning the steering wheel. This noise can typically be duplicated with a short drive on uneven road surfaces, then turning the vehicle left or right into a 90 degree turn.
Cause
This condition may be caused by the front stabilizer shaft insulator to front suspension crossmember brackets being out of specification.
Using the J 39570 Chassis Ear hooked up to each bracket may assist in determining if they are the source of the noise.
Correction
Replace both the front stabilizer shaft insulator brackets using the procedure listed below.
Raise and suitably support the vehicle.
Remove the front tire and wheel assemblies.
Reposition the intermediate steering shaft seal in order to gain access to the lower pinch bolt.
Remove the lower pinch bolt from the steering gear.
Support the front suspension crossmember with a suitable jackstand.
Remove the rear mounting bolts from the front suspension crossmember.
Remove the center mounting bolts from the front suspension crossmember.
Remove the front mounting bolts from the front suspension crossmember.
Lower the front suspension crossmember approximately 15 cm (6 in) by adjusting the jackstand down.
Remove the retaining bolts and stabilizer shaft insulator brackets.
Install the new stabilizer shaft insulator brackets and retaining bolts.
Tighten
Tighten the stabilizer shaft insulator bracket bolts to 66 N�m (49 lb ft).
Install the front mounting bolts to the front suspension crossmember.
Hand tighten the bolts.
Install the center mounting bolts to the front suspension crossmember.
Hand tighten the bolts.
Install the rear mounting bolts to the front suspension crossmember.
Hand tighten the bolts.
Tighten
Tighten the left rear bolt to 110 N�m(71 lb ft).
Tighten the right rear bolt to 110 N�m(71 lb ft).
Tighten the left front bolt to 110 N�m(71 lb ft).
Tighten the right front bolt to 110 N�m(71 lb ft).
Tighten the center bolts to 110 N�m(71 lb ft).
Tighten the stabilizer shaft insulator brackets bolts to 66 N�m(49 lb ft).
Install the lower pinch bolt from the steering gear.
Tighten
Tighten the bolt to 40 N�m(30 lb ft).
Install the front tire and wheel assemblies.
Tighten
Tighten the nuts in a criss-cross pattern 140 N�m (100 lb ft).
Lower the vehicle.
Parts Information
Part Number
Description
Qty
22660396
Clamp (Bracket), Front Stabilizer Shaft
2
Parts are currently available from GMSPO.
Warranty Information
For vehicles repaired under warranty, use:
Labor Operation
Description
Labor Time
E2180
Insulator and/or Bracket Front Stabilizer Shaft at Frame -- Replace Use Published Labor Operation Time
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Squeak Noise In Front End On Turns (Replace Strut Spring Seat) #04-03-08-015B - (May 9, 2005) Squeak Noise In Front End On Turns (Replace Strut Spring Seat)
1999-2004 Chevrolet Cavalier
2000-2003 Chevrolet Malibu
2004-2005 Chevrolet Classic
2000-2004 Oldsmobile Alero
2000-2005 Pontiac Grand Am
1999-2004 Pontiac Sunfire
Before performing the procedure in this bulletin, technicians should refer to Corporate Bulletin Number 02-03-08-008A if the vehicle has a rattle/creak or popping noise in the front end.
This bulletin is being revised to add the above Attention statement referencing Corporate Bulletin Number 02-03-08-008A. Please discard Corporate Bulletin Number 04-03-08-015A (Section 03 - Suspension).
Condition
Some customers may comment that the front end of the vehicle has a squeaking noise on left or right turns.
Cause
This condition may be caused by metal to metal contact between the strut mount and the spring seat.
Correction
Replace the strut spring seat, P/N 89047655. This new seat includes a deflector ring and will eliminate the contact between the strut mount and the spring seat. Refer to Strut, Strut Component And Or Spring Replacement.
The documents below are for Chevrolet Cavalier and Pontiac Sunfire.
� 1999 Document ID #173282.
� 2000 Document ID #529476.
� 2001 Document ID #635853.
� 2002-2003 Document ID #630647.
� 2004 Document ID #1173083.
The document below is for the Chevrolet Classic.
2004-2005 Document ID #1174192
The documents below are for the Chevrolet Malibu.
� 2000 Document ID #528929.
� 2001-2005 Document ID #640868.
The documents below are for the Oldsmobile Alero and Pontiac Grand Am.
� 2000 Document ID #526124.
� 2001-2003 Document ID #635853.
� 2004 Document ID #1173889.
� 2005 (Grand Am only) Document ID #1173889.
Parts Information
Part Number
Description
88964336
Seat, Front Spring (N Car)
89047655
Seat, Front Spring (J Car)
Parts are currently available from GMSPO.
Warranty Information
For vehicles repaired under warranty, use:
Labor Operation
Description
Labor Time
E3901
Seat And/Or Insulator, Front Spring (Upper And/Or Lower) - Left -- Replace Use Published Labor Time
E3900
Seat And/Or Insulator, Front Spring (Upper And/Or Lower) - Right -- Replace
E3907
Seat And/Or Insulator, Front Spring (Upper And/Or Lower) - Both -- Replace
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Wheel Squeak (Install Wheel Cover Insulators) #01-03-10-005C - (Oct 22, 2003) Wheel Squeak (Install Wheel Cover Insulators)
2000-2004 Chevrolet Cavalier with 14 and 15 Inch Wheel Covers
2000-2002 Pontiac Sunfire with 14 Inch Wheel Cover
2003-2004 Pontiac Sunfire with 15 Inch Wheel Cover
2000 Toyota Cavalier with 14 and 15 Inch Wheel Covers
This bulletin is being revised to update model years and provide additional material information for 2003 and 2004 vehicles. Please discard Corporate Bulletin Number 01-03-10-005B (Section 03 - Suspension).
This bulletin contains two different corrections; use the appropriate procedure depending on the model year of the vehicle.
Condition
Some customers may comment about a squeak type noise coming from the front or rear wheels. This condition is most apparent during cold weather and while driving at low speeds (0-24 km/h (0-15 mph)).
Cause
This condition may be caused by hard contact between the inner edge of the wheel cover and the outer edge of the steel rim.
Correction (2000-2002 Model Year)
Install insulators on the backside of all four wheel covers. Use the following service procedure and the part numbers listed below.
FIGURE Cavalier 14 Inch Wheel Cover(c)
FIGURE Cavalier 15 Inch Wheel Cover(c)
FIGURE Sunfire 14 Inch Wheel Cover(c)
Remove the wheel covers.
Clean the backside of each wheel cover using a mild liquid detergent in a distilled or deionized water solution. Rinse each wheel cover with clean water.
Dry each wheel cover using compressed air or a clean, lint-free, non-abrasive cloth.
After the wheel covers are completely dry, each wheel cover should be wiped with isopropyl alcohol on a clean, lint-free, non-abrasive cloth at the insulator locations. Refer to the illustrations above.
Important
There is no tolerance allowed for gaps between the insulator and the wheel cover lip. It is also ideal to have the insulator flush (1) against the rib, but there is a tolerance of up to 6 mm (0.236 in) for a gap (2) between the insulator and the rib.
Peel the red non-stick backing off of the insulator.
Carefully place the insulator onto the wheel cover so that the area under the lip is resting against the corner of the inside edge of the wheel cover lip.
Rotate the insulator until it is flush against the inside edge of the wheel cover lip.
Press down firmly on the insulator to ensure that the adhesive is bonding to the wheel cover.
Place another insulator in the next location by repeating Steps 5 through 8. There should be 10 insulators placed on each wheel cover.
Correction (2003 and 2004 Model Years)
Install insulator tape on the backside of all four wheel covers. Use the following procedure listed below.
FIGURE Sunfire Wheel Cover(c)
FIGURE Cavalier Wheel Cover(c)
Remove the wheel covers.
Clean the backside of each wheel cover using a mild liquid detergent in a distilled or deionized water solution. Rinse each wheel cover with clean water.
Dry each wheel cover using compressed air or a clean, lint-free, non-abrasive cloth.
After the wheel covers are completely dry, each wheel cover should be wiped with isopropyl alcohol on a clean, lint-free, non-abrasive cloth at the insulator locations. Refer to the illustrations above.
Cut (40-Cavalier or 36-Sunfire) 7 mm (.275 in) lengths of *3M(r) Squeak Reduction Tape 5430, P/N 06356.
Peel the non-stick backing off tape.
Carefully place the tape (insulator) onto the wheel cover's backside, outer most edge, as shown.
Press down firmly on the insulator to ensure that the adhesive is bonding to the wheel cover.
Repeat steps 6 through 8 with the remaining insulators. There should be (10-Cavalier or 9-Sunfire) insulators placed on each wheel cover.
Important
Also, place an insulator onto the wheel cover's backside at the location of the clip-on wheel balance weight.
*We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources.
Parts Information (2000-2002 Models Years) Part Number Description Qty
88950636
(2000-2002 Model Year Only)
Insulator Pkg, Wheel Trim Cover
4 pkgs.
(1 pkg. per Wheel)
Parts are currently available from GMSPO.
Part Information (2003 and 2004 Model Years) Part Number Description Qty Material Allowance
3M(r) 06356*
Squeak Reduction Tape
Length - 305 mm (12 in)
$2.00
* To obtain this product, check your dealers auto body shop. They may already have this tape or contact 3M(r) Automotive Aftermarket Helpline at 1-877-666-2277 and follow menu options to locate a store near you where it can be purchased.
Warranty Information
For vehicles repaired under warranty, use:
Labor Operation
Description
Labor Time
E0027
Cover, Wheel - Replace (All)
0.2 hr
In Other Labor Hours, add 0.5 hr for installing wheel cover insulators (authorization required).
My Car